Coated lead acid battery electrode plates; method for making coated electrode plates and lead acid batteries containing coated electrode plates

ABSTRACT

Disclosed are electrode plates for a lead acid battery. The electrode plates are formed of an electrode plate having a face, the electrode plate comprising a lead or lead alloy grid coated with an active material and the electrode plates having a porous, non-woven mat comprised of polymer fibers coating on the face of the electrode plate, as well as a method for making the coated electrode plates and lead acid batteries containing the coated electrode plates.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 16/396,542, filed Apr. 26, 2019, which is a continuation ofU.S. patent application Ser. No. 15/644,688, filed Jul. 7, 2017, nowU.S. Pat. No. 10,319,990, entitled “Coated Lead Acid Battery ElectrodePlates; Method for Making Coated Electrode Plates and Lead AcidBatteries Containing Coated Electrode Plates”, which application claimspriority benefit from U.S. Provisional Application No. 62/371,699, filedAug. 5, 2016, entitled “Coated Lead Acid Battery Components and Methodof Making Same,” the contents of each are hereby incorporated byreference in their entireties.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to the chemical and mechanical arts. Inparticular, this invention relates to electrode plates used in lead acidbatteries, a method for making the electrode plates and lead acidbatteries containing the electrode plates.

Background

A lead-acid battery includes a housing containing a positive electrodeplate and a negative electrode plate. The electrode plates are typicallyformed of an electrode grid coated with an active material. Whileprimarily constructed of lead, the electrode grids are often alloyedwith antimony, calcium, or tin to improve their mechanicalcharacteristics. Antimony is generally a preferred alloying material.The electrode plates are coated with active materials and separated byseparator, all in contact with an electrolyte. There is a long felt needfor electrode plates having improved mechanical and physical properties,such as durability and inertness in the harsh environment of a lead acidbattery.

Electrospinning is a technique for producing polymeric fibers.Electrospinning utilizes the electrostatic attraction between a chargedpolymer and a grounded or oppositely charged collection plate to producethe fibers. There are a number of electrospinning variations, includingusing polymer solutions and melts. In one of these variations, anelectrically charged polymer solution is fed through a small needle andthe solution is sucked towards a grounded collector. In anothervariation, an electrically charged polymer melt is fed through a smallneedle and it is the melt that is sucked towards a grounded collector.The charge dissipates and a non-woven web or mat of fibers is producedon the collector.

SUMMARY OF THE INVENTION

Now there has been discovered an electrode plate for a lead acid batterythat overcomes these and related disadvantages. In one aspect of theinvention, the electrode plate comprises an electrode plate comprising alead or lead alloy grid coated with an active material and a porous,non-woven mat comprised of polymer fibers coating on a face of theelectrode plate. In one aspect, the electrode plate is a positiveelectrode plate and, in one aspect, the electrode plate is a negativeelectrode plate.

In another aspect of the invention, the electrode plate is made byelectrospinning a polymer onto the face of the electrode plate to form aporous, non-woven mat coating comprised of polymer fibers on the surfaceof the electrode plate. And in another aspect, a lead acid batterycomprises a housing containing a negative electrode plate having a firstface and a positive electrode plate having a second face opposing thefirst face, where at least one of the opposing faces comprises a coatingof a porous, non-woven mat comprised of polymer fiber, a separatordisposed between the first and second electrode plate faces and anelectrolyte immersing all of the negative electrode plate, the positiveelectrode plate and the separator. In one aspect, the lead acid batteryis a flooded lead acid battery or a valve regulated lead acid battery.And in one aspect, the valve regulated lead acid battery is an AGS leadacid battery or a gel lead acid battery.

In one aspect of the invention, the lead alloy grid is a lead-antimony,a lead-calcium or a lead-tin alloy grid. In another aspect of theinvention, the alloy is a lead-antimony. And in one aspect, the activematerial is a lead oxide active material.

In one aspect of the invention, the fibers have a fiber diameter of fromabout 5 nm and about 30 μm and, in one aspect, the fibers have a fiberdiameter of from about 500 nm to about 1 μm. In one aspect, the polymercoating has a surface area of from about 5 m²/g to about 500 m²/g and,in one aspect, the polymer fiber coating has a surface area of from 50m2/g to about 200 m2/g.

In one aspect, the polymer fiber coating has a porosity of from 30% toabout 90% and, in one aspect, the polymer fiber coating has a porosityof from about 50% to about 70%. In one aspect, the polymer fiber coatinghas a thickness of from about 2 μm to about 2 mm, in another aspect, thepolymer fiber coating has a thickness of from about 5 μm to about 500 μmand in another aspect, the polymer fiber coating has a thickness of fromabout 20 μm to about 250 μm.

In one aspect, the polymer fibers are cellulose acetate, polystyrene,polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylic acid,polyvinyl alcohol, polylacetic acid, polyethylene-co-vinyl acetate,polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide,polymethacrylate, polyamide, polycaprolactone, polyethylimide,polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinylchloride, polyvinylidene chloride, polyvinylidene fluoride,poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine,polylactic acid, polypropylene, polybutylene, polybutyleneterephthalate, polyamide, polyimide, polycarbonate,polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene,poly(methylmethacrylate), polyoxymethylene, polysulfone,styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber,ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, naturalrubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile,poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly(3-hydroxybutrate-co-3-hydroxyvalerate),polystyrene-block-polyisoprene-block-polystyrene fibers or combinationsthereof. In another aspect, the polymer fibers are cellulose acetate,polystyrene, polyethylene or Nylon 6 fibers.

In one aspect, the polymer fiber coating further comprises an activeagent. In another aspect, the active agent is natural rubber, RSS 1 or V60 rubber, a macromolecule, a chelating agent, silica, carbon black orcombinations thereof.

In one aspect, the polymer to be electrospun spun is formulated as asolution comprising 3the polymer and a solvent for the polymer. And inone aspect, the solvent is formic acid, dimethyl formamide,n-methylpyrrolidone, acetone, ethyl acetate, propyl acetate, water,dichloromethane, tetrahydrofuran, isopropyl alcohol, dicloromethane,ethanol, methanol, chloroform, acid acid, trifluoroacetic acid,trifluoroethanol, hexafluoro propanol, dimethylacetamide, carbondisulfide, cyclohexane, toluene, N-methylmorpholine, xylenes anddimethylsulfoxide or combinations thereof. In another aspect, thesolvent is formic acid or dimethyl formamide.

In one aspect, the polymer to be electrospun spun is formulated as apolymer melt. And in one aspect, the polymer solution or polymer meltformulation further comprises an active agent. In still another aspect,the active agent is natural rubber, RSS 1 or V 60 rubber, amacromolecule, a chelating agent, silica, carbon black or combinationsthereof.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, together with the specification, illustrateexemplary embodiments, and, together with the description, serve toexplain the principles of these embodiments.

FIG. 1 is a partially cutaway perspective view illustrating one aspectof a lead acid battery with electrodes in accordance with one aspect ofthe invention.

FIG. 2 is a partially cutaway front elevation view illustrating oneaspect of an electrode plate coated with a porous, non-woven matcomprised of polymer fibers in accordance with one aspect of theinvention.

DETAILED DESCRIPTION OF THE INVENTION

Particular embodiments of the invention are described below inconsiderable detail for the purpose of illustrating its principles andoperation. However, various modifications may be made, and the scope ofthe invention is not limited to the exemplary embodiments describedbelow. For example, while specific reference is made to flooded leadacid batteries, the invention is of equal use with other lead acidbatteries, such as valve regulated lead acid batteries, includingbi-polar lead acid batteries, AGS lead acid batteries and gel lead acidbatteries.

FIG. 1 is a partially cutaway perspective view illustrating one aspectof a flooded lead acid battery with electrode plates in accordance withone aspect of the invention. The lead-acid battery 10 includes a housing12 having positive and negative terminal posts 14 extending through thetop of the housing to allow for electrical clamps to connect to thebattery in operation.

A number of vertical partition walls 16 create a plurality of separatecell compartments 17. Each cell compartment contains a vertical stack ofnegative plates 18 and positive plates 20 having opposing faces spacedapart by separators 22 all immersed in an electrolyte 24, such assulfuric acid (H₂SO₄).

Referring now to FIG. 2 , there is shown a partially cutaway frontelevation view illustrating one aspect of an electrode plate havingcoating with a porous, non-woven mat comprised of polymer fibers inaccordance with one aspect of the invention. The negative and positiveelectrode plates 18, 20 are constructed with an underlying electrodegrid 26. The electrode grid is primarily formed of lead and, typically,is alloyed with antimony, calcium or tin, generally with antimony.

In one aspect of the invention, an active material paste 28 is appliedto the electrode grid. The positive and negative active material pastesgenerally comprise lead oxide (PbO) or lead (II). Suitable electrodeplates are described in U.S. Pat. No. 8,546,006, which patent is hereinincorporated by reference.

Now in accordance with one aspect of the invention, there has beendiscovered lead acid battery electrode plates 10 having a porous,non-woven web or mat coating 30 comprised of polymeric fibers on atleast one face of the positive electrode plates and/or the negativeelectrode plates. The polymer fiber coating, which in one aspect is aporous, non-woven mat, can be made of any suitable polymer fiber.Representative polymer fibers include, without limitation, celluloseacetate, polystyrene, polyethylene and Nylon 6 polymer fibers. Othersuitable polymer fibers include, without limitation carboxymethylcellulose (CMC), Polyacrylic acid (PAA), Polyvinyl alcohol (PVA),Polylacetic acid (PLA), Polyethylene-co-vinyl acetate, PEVA/PLA,Polymethyacrylate (PMMA)/tetrahydroperfluorooctylacrylate (TAN),Polyethylene oxide (PEO), Polymethacrylate (PMMA), Polyamide (PA),Polycaprolactone (PCL), Polyethyl imide (PEI) Polycaprolactam,Polyethylene terephthalate (PET), Polyphenyl ether (PPE), Polyvinylchloride (PVC), Polyvinylidene chloride (PVDC), Polyvinylidene fluoride(PVDF), Poly(vinylidenefluoride-co-hexafluoropropylene (PVDF-HFP),Polyvinyl-pyridine, Polylactic acid (PLA), Polyolefins including but notlimited to, Polypropylene (PP), Polybutylene (PB), Polybutyleneterephthalate (PBT), Polyamide (PA), Polyimide (PI), Polycarbonate (PC),Polytetrafluoroethylene (PTFE), Polyester (PE), Acrylonitrile butadienestyrene (ABS), Poly(methyl methacrylate) (PMMA), Polyoxymethylene (POM),Polysulfone (PES), Styrene-acrylonitrile (SAN), Polyacrylonitrile (PAN),Styrene-butadiene rubber (SBR), Ethylene vinyl acetate (EVA), Styrenemaleic anhydride (SMA), Polyisoprene (PI), Natural Rubber (NR),Cellulose, Cellulose Acetate (CA), Polyaniline (PANI), Polyacrylonitrile(PAN), Poly (ε-caprolactone) (PCL), Chitosan, Gelatin, Polyurethanes(PU), Poly (3-hydroxybutrate-co-3-hydroxyvalerate) (PHBV),polystyrene-block-polyisoprene-block-polystyrene fibers and combinationsthereof.

It is a benefit of the polymer fiber coatings 30 that they are inert anddurable. The polymer fiber coatings can survive the environment inside alead acid battery. The non-woven web deposited on the surface of theplate will not get washed/removed from the surface of the plate.

It is a distinct advantage of the invention that the polymer fibers arenanofibers having a small fiber diameter, large surface area, highporosity and a controlled thickness. For example, in some embodiments,the fibers have a fiber diameter of from about 5 nm and about 30 μm andin some embodiments, the fibers have a fiber diameter of from about 500nm to about 1 μm. In some other embodiments, the coating 30 has asurface area of from about 5 m²/g to about 500 m²/g, and in some otherembodiments, the coating has a surface area of from about 50 m²/g toabout 200 m²/g.

And, in some embodiments, the coating has a porosity of from about 30%to about 90%, in some other embodiments, the coating has a porosity offrom about 50% to about 70%. And in some still other embodiments, thecoating has a thickness of from about 2 μm to about 2 mm, in someembodiments, the coating has a thickness of from about 5 μm to about 500μm, and in some embodiments, the coating has a thickness of from about20 μm to about 250 μm.

The resulting non-woven web or mat of polymeric fiber improves themechanical and physical properties of the electrode plates. For example,porosity can be controlled to allow electrolyte access to plate surface.It is an advantage of the invention that the unwoven mat coatings arevery porous and allow easy transport of the H₂SO₄ electrolyte 24 to theelectrode plate. H₂SO₄ is a medium for the electrochemical reactionsthat take place in the battery. H₂SO₄ is also a reactant, and it is adrawback of other less porous coatings that they may reduce itsreactivity.

Further, the coatings 30 are durable and flexible. The coatings canexpand and contract along with the electrode plates. Still further, thecoatings can introduce functionalities via the action of the coating oractive agents contained within the coating. These can include but arenot limited to improved micro/nanostructure of the plate throughoptimized crystallization. The coating can establish nucleating pointsand/or face selective adsorption for controlled crystal growth ofparticles. The coating can introduce areas of high conductivity andcapacitance to accelerate the electrochemical processes, reduce gassingand poisoning of plates, e.g. inhibiting migration of antimony to thenegative plates. The coating can also produce solubility enhancement oflead based particles undergoing electrochemical conversion.

In another aspect of the invention, the coating 30 additionally containsat least one active agent. The active agent can be any material thatfurther enhances the mechanical and physical properties of the coating.Useful active agents include, without limitation, natural rubber toreduce the migration of antimony from the positive to the negativeplates (18, 20) and diminish the impact of antimony poisoning such aselectrolyte expenditure and loss of capacity; other rubbers, such as RSS1 and V 60 rubber; macromolecules, such as lignin, including Indulin AT,to decrease sulfation, chelating agents, such as acetylacetone and EDTAand carbon materials, including graphite and carbon black, such asCyPbrid 1 to increase charge acceptance and decrease sulfation. Othersuitable active ingredients include sulfates, such as barium sulfatewhich can be employed in the unwoven mat as a nucleating agent and tinsulfate which can be integrated into the unwoven mat to dissolve intothe lead acid battery electrolyte and reduce the particle size of PbO₂.In still a further aspect of the invention, carbon additives, such asgraphite, can be introduced into the unwoven mat to produce areas ofconductivity in the flooded lead acid battery and/or change thepotential of the electrodes.

The amount of active agent in the coating 30 can vary depending on theactive agent, the polymer fiber and the properties of the coating.Typically, the amount of active agent is from about 200:1 to about 1:1,and in some embodiments, from about 100:1 to about 10:1, based onweight:weight ratio.

In one aspect, the electrode grids 28 are primarily construct of leadand, in some embodiments, the lead is alloyed with antimony, calcium, ortin to improve the mechanical characteristics of the electrode plates.Antimony is generally a preferred alloying material. According to oneembodiment, the positive electrode plates are made from a lead-antimonyalloy. In one embodiment, the electrode grids are alloyed with about 2wt % to about 11 wt % antimony. In another embodiment, the electrodegrids are alloyed with between about 2 wt % and about 6 wt % antimony.The negative electrode grids are similarly made from an alloy of leadand antimony, but generally include less antimony than the alloy usedfor the positive electrode grids. The negative electrode grids also tendto be somewhat thinner than the positive electrode grids.

In another aspect of the invention, an active material paste 28 isapplied to the electrode grid 26. The positive and negative activematerial pastes generally comprise lead oxide (PbO) or lead (II).

In one aspect of the invention, the coating 30 is porous, nanofiber matformed by an electrospinning. process. And in one aspect, theelectrospun polymeric fiber coating is formed using a charged polymersolution and a lead acid battery electrode plate as the grounded oroppositely charged collection plate. It is an advantage of theelectrospinning method in accordance with the invention that a largevariety of materials and solvents can be combined in the polymericsolution in order to tailor specific properties and functionalities.Suitable polymers include, without limitation, cellulose acetate,polystyrene, polyethylene and Nylon 6 fibers. Other suitable polymersinclude carboxymethyl cellulose (CMC), Polyacrylic acid (PAA), Polyvinylalcohol (PVA), Polylacetic acid (PLA), Polyethylene-co-vinyl acetate,PEVA/PLA, Polymethyacrylate (PMMA)/tetrahydroperfluorooctylacrylate(TAN), Polyethylene oxide (PEO), Polymethacrylate (PMMA), Polyamide(PA), Polycaprolactone (PCL), Polyethyl imide (PEI) Polycaprolactam,Polyethylene terephthalate (PET), Polyphenyl ether (PPE), Polyvinylchloride (PVC), Polyvinylidene chloride (PVDC), Polyvinylidene fluoride(PVDF), Poly(vinylidenefluoride-co-hexafluoropropylene (PVDF-HFP),Polyvinyl-pyridine, Polylactic acid (PLA), Polyolefins including but notlimited to, Polypropylene (PP), Polybutylene (PB), Polybutyleneterephthalate (PBT), Polyamide (PA), Polyimide (PI), Polycarbonate (PC),Polytetrafluoroethylene (PTFE), Polyester (PE), Acrylonitrile butadienestyrene (ABS), Poly(methyl methacrylate) (PMMA), Polyoxymethylene (POM),Polysulfone (PES), Styrene-acrylonitrile (SAN), Polyacrylonitrile (PAN),Styrene-butadiene rubber (SBR), Ethylene vinyl acetate (EVA), Styrenemaleic anhydride (SMA), Polyisoprene (PI), Natural Rubber (NR),Cellulose, Cellulose Acetate (CA), Polyaniline (PANI), Polyacrylonitrile(PAN), Poly (ε-caprolactone) (PCL), Chitosan, Gelatin, Polyurethanes(PU), Poly (3-hydroxybutrate-co-3-hydroxyvalerate) (PHBV),polystyrene-block-polyisoprene-block-polystyrene fibers and combinationsthereof.

Suitable solvents include liquids that are solvents for the polymer andthat can sustain a charge, i.e., form a charged polymer solution.Representative solvents include, without limitation, formic acid anddimethyl formamide (DMF), with Nylon 6 in formic acid and celluloseacetate in DMF being presently preferred polymeric solution. Othersuitable solvents include N-Methylpyrrolidone (NMP), acetone, ethylacetate, propyl acetate, water, dichloromethane, tetrahydrofuran,isopropyl alcohol, dicloromethane, ethanol, methanol, chloroform, acidacid, trifluoroacetic acid, trifluoroethanol, hexafluoro propanol,dimethylacetamide, carbon disulfide, cyclohexane, toluene,N-methylmorpholine, xylenes and dimethylsulfoxide and combinationsthereof. Typically, the amount of polymer in the solution is from about5% to about 30%, in some embodiments, about 10% to about 25%, and insome embodiments, from about 15 to about 20%, based on % (w/v).

And in one aspect of the invention, the polymer solution contains atleast one active agent to impart additional beneficial properties to thecoatings. Representative active agents include, without limitation,natural rubber, synthetic rubber, such as RSS 1 and V 60 rubber,macromolecules, such as lignin, including Indulin AT, in a suitablesolvent, such as DMF, to decrease sulfation. Other active ingredientsinclude chelating agents, such as acetylacetone and EDTA, silica andcarbon black, such as CyPbrid 1 to increase charge acceptance anddecrease sulfation.

The solvent for the active agent can be the same as or different thanthe solvent for the polymer. For example, in one embodiment the activeagent is Indulin AT and the solvent for the Indulin AT is dimethylformamide (DMF). Typically, the amount of active agent in the polymersolution is from about 10% to about 50%, in some embodiments, about 20%to about 40%, and in some embodiments, from about 25% to about 40%,based on % (w/v).

Representative embodiments of the polymeric solution include:

-   -   18:1 polystyrene:indulin at 25% (w/v) in DMF    -   25% (w/v) Nylon-6 in Formic acid or    -   10:1 cellulose acetate:indulin AT 20% (w/v) in DMF

Parameters which may affect the formation of fibers include solutionproperties (e.g., conductivity, surface tension, viscosity, andelasticity), the distance between the capillary tube, electric potentialat the capillary tip, and ambient parameters (e.g., humidity, solutiontemperature, and air velocity). In one aspect of the inventive method, aspinneret is connected to a high voltage direct current power supply,such as a 5 to 30 kV direct current power supply. The voltage supply maydepend upon such factors as the type of polymer used, the desiredporosity, and the rate of production.

The polymer solution is loaded into the spinneret and the electricallycharged liquid extruded through the tip of the spinneret toward thesurface of the electrode plate collector at a constant rate using asuitable pump. Typically, the flow rate is from about 0.001 ml/min toabout 10 ml/min, in some embodiments, about 0.025 to about 1 ml/min, andin some embodiments, from about 0.1 to about 1 ml/min. The diameter ofthe fibers may be controlled by adjusting the solvent concentration inthe polymer solution, adjusting a gap distance between the tip of themetallic needle and the grounded surface of the electrode structure.

And in one aspect, charged threads of the polymer solution are drawn toa negatively charged or grounded electrode plate collector positioned ata predetermined distance below the tip of the spinneret and the polymersolution coated on the surface of the plate until the desired coverageis achieved. In some embodiments, the plate is positioned from about 10mm to about 1,000 cm below the tip of the spinneret, in someembodiments, about 1 to about 50 cm below the tip of the spinneret, andin some embodiments, from about 5 to about 20 cm below the tip of thespinneret. It is an advantage of the inventive method that it can beemployed as a continuous process.

In accordance with another embodiment, the porous, non-woven mat isformed from a polymer melt. Polymers which are molten at hightemperatures may be used in the melt process. Electrospinning of thepolymer melt is similar to the process for electrospinning of thepolymer solution, however, electrospinning of the polymer melt isperformed in a vacuum environment. The charged melt jet, substrate thatthe melt is deposited on are typically encapsulated in a vacuumenvironment. Exemplary polymers which may be electrospun in melt forminclude Polyethylene (PE), Polypropylene (PP), Nylon 12, PA-12,Polyethylene terephthalate (PET), Polyethylene napthalate (PEN), PET/PENblends, and combinations thereof.

In some embodiments, the polymer melt contains at least one active agentto impart additional beneficial properties to the coatings.Representative active agents include, without limitation, naturalrubber, synthetic rubber, such as RSS 1 and V 60 rubber, macromolecules,such as lignin, including Indulin AT. Other active ingredients includechelating agents, such as acetylacetone and EDTA, silica and carbonblack, such as CyPbrid 1.

In accordance with another aspect of the invention, the coated electrodeplates 18, 20 are incorporated in flooded lead acid batteries 10comprising a housing 12. The housing contains a negative electrode plate18 with a first face and a positive electrode plate 20 with a secondface opposing the first face; a separator 24 positioned between thefirst and second electrode plate faces and an electrolyte 26 immersingall of the negative electrode plate, the positive electrode plate andthe separator.

The electrospun webs in accordance with the invention provide a numberof benefits, such as improving the physical and mechanical properties ofthe lead acid batteries and imparts a number of positive effects onbatteries' function. For example, dendrite formation on a negative platecan lead to short circuits that have detrimental effect on the operationof a battery. The deposition of a porous mat reduces this as the fibersact as a barrier of the dendrite growth on the +batteries' surface.

Another problem lead acid batteries encounter when working in a state ofpartial charge is the formation of hard sulfation of PbSO₄ in thebattery plates. This can lead to reduction in capacity and cycle life ofthe battery. The electrospun coating can reduce this hard sulfation byintegration of additives that control the nucleation of PbSO₄ crystalsor bind to PbSO₄ limiting the crystal size growth on the surface.

From the above description of the invention, those skilled in the artwill perceive improvements, changes and modifications. Suchimprovements, changes, and modifications are within the skill of the artand are intended to be covered by the appended claims.

What we claim is:
 1. An electrode plate for a lead acid battery having acoating comprising: an electrode plate for a lead acid battery having aface, the electrode plate comprising a lead or lead alloy grid coatedwith an active material and a porous, non-woven mat comprised of polymerfibers coating on the face of the electrode plate.
 2. The electrodeplate of claim 1 wherein the lead alloy is a lead-antimony, alead-calcium or a lead-tin grid.
 3. The electrode plate of claim 2wherein the alloy is a lead-antimony alloy.
 4. The electrode plate ofclaim 2 wherein the active material is a lead oxide active material. 5.The electrode plate of claim 1 wherein the polymer fibers have a fiberdiameter of from about 5 nm and about 30 μm.
 6. The electrode plate ofclaim 1 wherein the polymer fibers have a fiber diameter of from 500 nmto about 1 μm.
 7. The electrode plate of claim 1 wherein the polymerfiber coating has a surface area of from 5 m2/g to about 500 m2/g. 8.The electrode plate of claim 1 wherein the polymer fiber coating has asurface area of from 50 m2/g to about 200 m2/g.
 9. The electrode plateof claim 1 wherein the polymer fiber coating has a porosity of from 30%to about 90%.
 10. The electrode plate of claim 1 wherein the polymerfiber coating has a porosity of from about 50% to about 70%.
 11. Theelectrode plate of claim 1 wherein the polymer fiber coating has athickness of from about 2 μm to about 2 mm.
 12. The electrode plate ofclaim 1 wherein the polymer fiber coating has a thickness of from about5 μm to about 500 μm.
 13. The electrode plate of claim 1 wherein thepolymer fiber coating has a thickness of from about 20 μm to about 250μm.
 14. The electrode plate of claim 1 wherein the polymer fibers arecellulose acetate, polystyrene, polyethylene, Nylon 6, carboxymethylcellulose, polyacrylic acid, polyvinyl alcohol, polylacetic acid,polyethylene-co-vinyl acetate,polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide,polymethacrylate, polyamide, polycaprolactone, polyethylimide,polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinylchloride, polyvinylidene chloride, polyvinylidene fluoride,poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine,polylactic acid, polypropylene, polybutylene, polybutyleneterephthalate, polyamide, polyimide, polycarbonate,polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene,poly(methyl methacrylate), polyoxymethylene, polysulfone,styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber,ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, naturalrubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile,poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly(3-hydroxybutrate-co-3-hydroxyvalerate),polystyrene-block-polyisoprene-block-polystyrene fibers or combinationsthereof.
 15. The electrode plate of claim 14 wherein the polymer fibersare cellulose acetate, polystyrene, polyethylene or Nylon 6 fibers. 16.The electrode plate of claim 1 wherein the polymer fiber coating furthercomprises an active agent.
 17. The electrode plate of claim 16 whereinthe active agent is natural rubber, RSS 1 or V 60 rubber, amacromolecule, a chelating agent, silica, carbon black or combinationsthereof.
 18. The electrode plate of claim 1 wherein the electrode plateis a positive electrode plate for a lead acid battery.
 19. The electrodeplate of claim 1 wherein the electrode plate is a negative electrodeplate for a lead acid battery.
 20. A method for coating an electrodeplate for a lead acid battery comprising the step of: electrospinning apolymer onto the surface of an electrode plate collector, the electrodeplate collector comprising a lead or lead alloy grid coated with anactive material, to form a porous, non-woven mat coating comprised ofpolymer fibers on the surface of the electrode plate collector.
 21. Themethod of claim 20 wherein the lead alloy grid is a lead-antimony, alead-calcium or a lead-tin alloy grid.
 22. The electrode plate of claim21 wherein the alloy is a lead-antimony alloy.
 23. The electrode plateof claim 22 wherein the active material is a lead oxide active material.24. The method of claim 20 wherein the polymer fibers comprising theporous, non-woven mat coating have a fiber diameter of from 5 nm andabout 30 μm.
 25. The method of claim 20 wherein the polymer fiberscomprising the porous, non-woven mat coating have a fiber diameter offrom 500 nm to about 1 μm.
 26. The method of claim 20 wherein thepolymer fiber coating has a surface area of from 5 m2/g to about 500m2/g.
 27. The method of claim 20 wherein the polymer fiber coating has asurface area of from 50 m2/g to about 200 m2/g.
 28. The method of claim20 wherein the polymer fiber coating has a porosity of from 30% to about90%.
 29. The method of claim 20 wherein the polymer fiber coating has aporosity of from about 50% to about 70%.
 30. The method of claim 20wherein the polymer fiber coating has a thickness of from about 2 μm toabout 2 mm.
 31. The method of claim 20 wherein the polymer fiber coatinghas a thickness of from about 5 μm to about 500 μm.
 32. The method ofclaim 20 wherein the polymer fiber coating has a thickness of from about20 μm to about 250 μm.
 33. The method of claim 20 wherein the polymerfibers are cellulose acetate, polystyrene, polyethylene, Nylon 6,carboxymethyl cellulose, polyacrylic acid, polyvinyl alcohol,polylacetic acid, polyethylene-co-vinyl acetate,polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide,polymethacrylate, polyamide, polycaprolactone, polyethylimide,polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinylchloride, polyvinylidene chloride, polyvinylidene fluoride,poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine,polylactic acid, polypropylene, polybutylene, polybutyleneterephthalate, polyamide, polyimide, polycarbonate,polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene,poly(methyl methacrylate), polyoxymethylene, polysulfone,styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber,ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, naturalrubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile,poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly(3-hydroxybutrate-co-3-hydroxyvalerate),polystyrene-block-polyisoprene-block-polystyrene fibers or combinationsthereof.
 34. The method of claim 33 wherein the polymer fibers arecellulose acetate, polystyrene, polyethylene or Nylon 6 fibers.
 35. Themethod of claim 20 further comprising the step of formulating thepolymer to be electrospun spun as a solution comprising the polymer anda solvent for the polymer.
 36. The method of claim 35 wherein thepolymer solution further comprises an active agent.
 37. The method ofclaim 36 wherein the active agent is natural rubber, RSS 1 or V 60rubber, a macromolecule, a chelating agent, silica, carbon black orcombinations thereof.
 38. The method of claim 35 wherein the solvent isformic acid, dimethyl formamide, n-methylpyrrolidone, acetone, ethylacetate, propyl acetate, water, dichloromethane, tetrahydrofuran,isopropyl alcohol, dicloromethane, ethanol, methanol, chloroform, acidacid, trifluoroacetic acid, trifluoroethanol, hexafluoro propanol,dimethylacetamide, carbon disulfide, cyclohexane, toluene,N-methylmorpholine, xylenes and dimethylsulfoxide or combinationsthereof.
 39. The method of claim 38 wherein the solvent is formic acidor dimethyl formamide.
 40. The method of claim 33 further comprising thestep of formulating the polymer to be electrospun spun as a polymermelt.
 41. The method of claim 40 wherein the polymer melt furthercomprises an active agent.
 42. The method of claim 41 wherein the activeagent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, achelating agent, silica, carbon black or combinations thereof.
 43. Themethod of claim 33 wherein the electrode plate collector is a positiveelectrode plate for a lead acid battery.
 44. The method of claim 33wherein the electrode plate collector is a negative electrode plate fora lead acid battery.
 45. A lead acid battery comprising: a housingcontaining a negative electrode plate for a lead acid battery having afirst face and a positive electrode plate for a lead acid battery havinga second face opposing the first face, where the electrode plates arecomprised of a lead or lead alloy grid coated with an active material; aseparator disposed between the first and second electrode plate facesand an electrolyte immersing the negative electrode plate, the positiveelectrode plate the separator; at least one of the opposing faces acoating of a porous, non-woven mat comprised of polymer fiber.
 46. Theelectrode plate of claim 45 wherein the lead alloy grid is alead-antimony, a lead-calcium or a lead-tin alloy grid.
 47. Theelectrode plate of claim 46 wherein the alloy is an antimony.
 48. Theelectrode plate of claim 45 wherein the active material is a lead oxideactive material.
 49. The lead acid battery of claim 45 wherein thepolymer fibers have a fiber diameter of from 5 nm and about 30 μm. 50.The electrode plate of claim 45 wherein the polymer fibers have a fiberdiameter of from 500 nm to about 1 μm.
 51. The lead acid battery ofclaim 45 wherein the polymer fiber coating has a surface area of from 5m2/g to about 500 m2/g.
 52. The lead acid battery of claim 45 whereinthe polymer fiber coating has a surface area of from 50 m2/g to about200 m2/g.
 53. The lead acid battery of claim 45 wherein the polymerfiber coating has a porosity of from 30% to about 90%.
 54. The lead acidbattery of claim 45 wherein the polymer fiber coating has a porosity offrom about 50% to about 70%.
 55. The lead acid battery of claim 45wherein the polymer fiber coating has a thickness of from about 2 μm toabout 2 mm.
 56. The lead acid battery of claim 45 wherein the polymerfiber coating has a thickness of from about 5 μm to about 500 μm. 57.The lead acid battery of claim 45 wherein the polymer fiber coating hasa thickness of from about 20 μm to about 250 μm.
 58. The lead acidbattery of claim 45 wherein the polymer fibers are cellulose acetate,polystyrene, polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylicacid, polyvinyl alcohol, polylacetic acid, polyethylene-co-vinylacetate, polymethyacrylate/tetrahydroperfluorooctylacrylate,polyethylene oxide, polymethacrylate, polyamide, polycaprolactone,polyethylimide, polycaprolactam, polyethylene terephthalate, polyphenylether, polyvinyl chloride, polyvinylidene chloride, polyvinylidenefluoride, poly(vinylidenefluoride-co-hexafluoropropylene,polyvinyl-pyridine, polylactic acid, polypropylene, polybutylene,polybutylene terephthalate, polyamide, polyimide, polycarbonate,polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene,poly(methyl methacrylate), polyoxymethylene, polysulfone,styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber,ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, naturalrubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile,poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly(3-hydroxybutrate-co-3-hydroxyvalerate),polystyrene-block-polyisoprene-block-polystyrene fibers or combinationsthereof.
 59. The lead acid battery of claim 58 wherein the polymerfibers are cellulose acetate, polystyrene, polyethylene or Nylon 6fibers.
 60. The lead acid battery of claim 45 wherein the polymer fibercoating further comprises an active agent.
 61. The lead acid battery ofclaim 60 wherein the active agent is natural rubber, RSS 1 or V 60rubber, a macromolecule, a chelating agent, silica, carbon black orcombinations thereof.
 62. The lead acid battery of claim 45 wherein thelead acid battery is a flooded lead acid battery or a valve regulatedlead acid battery.
 63. The lead acid battery of claim 62 wherein thelead acid battery is a flooded lead acid battery.
 64. The lead acidbattery of claim 62 wherein the lead acid battery is a valve regulatedlead acid battery.
 65. The lead acid battery of claim 64 wherein thevalve regulated lead acid battery is an AGS lead acid battery or a gellead acid battery.